Note: Descriptions are shown in the official language in which they were submitted.
CA 03118515 2021-05-03
WO 2020/127556
PCT/EP2019/086055
METHOD FOR PRODUCING A VENEERED WOODEN MATERIAL AND
WOODEN MATERIAL COMPRISING A SUPPORTING PLATE AND AT
LEAST TWO VENEERS
The invention relates to a method for producing a wooden material wherein a
support-
ing plate and at least two veneers are connected by a synthetic resin, as well
as a wood-
en material board that is coated with at least two veneers.
Wooden materials that have a veneered surface are known from e. g. EP 2 902
196 Al.
They consist of a wooden material support (e. g. HDF or high-density fiber
board, OSB
board, particle board), to which a synthetic resin layer is applied, which
affixes a veneer
by the synthetic resin penetrating the veneer. The veneers used typically have
a thick-
ness of 0.8 mm to 2.5 mm. The documents US 2011/162308 Al, WO 2017/162926 Al,
and EP 2 353 861 Al also disclose veneered wooden material boards and methods
for
producing them.
Veneered surfaces are highly valued as real wood surfaces. They have a
pleasing surface
feel and generate pleasing acoustic conditions. Veneered surfaces are
perceived as of
particular high quality, wherein the thickness of the veneer applied is one of
the criteria
being evaluated. At the same time, veneers that are suitable as a cover layer
for panels
are the most expensive component of the wooden composite.
Therefore, this results in the object of providing a wooden material, wherein
a high-
quality veneer surface is provided on a supporting plate in a cost-effective
manner.
This object is solved by a method according to claim 1 as well as by a wooden
material
board according to claim 9. The dependent claims claim particular embodiments
of the
invention.
The method for producing a wooden material is based on a supporting plate and
a first,
non-external veneer, both of which are connected to one another by means of a
synthe-
tic resin on a first surface of the supporting plate. According to the
invention, at least a
second veneer is applied to the first surface of the supporting plate, though,
deviating
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 2 -
from the prior art. The second veneer is applied to the first veneer. To
connect support-
ing plate and veneer, a liquid synthetic resin is applied in excess to
supporting plate
and/or veneer. Excess here means the quantity of synthetic resin which, in
relation to
the quantity of synthetic resin required for gluing purposes, is additionally
applied to
supporting plate and/or veneer. Either, a person skilled in the art will know
the quanti-
ty of synthetic resin required for gluing purposes from the instructions of
the synthetic
resin manufacturer, or they will know based on their technical knowledge, what
syn-
thetic resin quantity will be required for gluing veneer and supporting plate
to one
another. A typical application quantity for the synthetic resin that is used
for affixing a
veneer without excess quantity can amount to e.g. 60 g/m2 to 100 g/m2, most
often 80
g/m2. The quantity of synthetic resin required for gluing purposes can also
potentially
be determined by means of a few tests for orientation. Once the quantity of
synthetic
resin required for gluing purposes is known, the excess quantity can be
determined
with a few tests. Then, the synthetic resin applied in excess is dried but not
cured.
Supporting plate and veneer are assembled to form a stack of material to be
pressed,
and the stack of material to be pressed is compressed in a high-pressure press
to form a
wooden material.
In this manner, on the one hand, a thick veneer application can be achieved
wherein a
first cost-effective veneer and, on top of that, a high-quality, much thinner
second
veneer is used, such that a high-quality but cost-effective wooden material
board with a
veneer surface is provided. Thus, for example by using a 1.5 mm thick cost-
effective
poplar veneer as a first veneer and a 0.6 mm thick expensive oak veneer, a
veneer layer
on the supporting plate of 2.1 mm can be achieved at lower cost than by using
a 2.1 mm
oak veneer. The thickness of the at least one second veneer preferably amounts
to 0.15
times to 0.3 times that of the first veneer. In general, if several veneers
are used, the
thickness of the outer-most veneer, which is also called the second veneer
within the
context of this invention, and which forms the visible surface of the wooden
material,
amounts to 0.15 times to 0.3 times the thickness of the veneers arranged
underneath
the outer-most veneer.
Furthermore, veneers of different colors can be used, such that a darker
second veneer
covers a lighter colored first veneer. By partially removing the second
veneer, the first,
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 3 -
lighter colored veneer becomes visible, such that for example the impression
of inlaid
wood work is generated. The color sequence described above is only one
possible
arrangement of at least two veneers on the first surface of a supporting
plate. It is to be
expressly understood that any given sequence of veneers of different colors
can be
arranged on the first surface of a supporting plate, and that with more than
two ve-
neers, the partial removal of the first and second veneers will generate an
aesthetically
attractive effect. The removal of the veneers down to the first surface of the
supporting
plate, too, generates an attractive aesthetic effect at low cost. A typical
application of
partial removal is the application of a chamfer at the transition from the
first surface of
a supporting plate to a side face. In this area, the veneers are then visible
side by side.
The surface designs described above appear to be of high-value. According to
the
invention, they can be provided easily and cost-effectively.
An embodiment of the method according to the invention provides that at least
three,
four, five, or more veneers are applied to the first surface of a supporting
plate. Any
given number of veneers can be applied to the first surface of a supporting
plate on top
of one another. The method according to the invention is limited only by the
perfor-
mance of the press described hereafter, which must be capable of softening the
dried
synthetic resin applied in excess through the veneers arranged on top of one
another
and to allow it to cure. Furthermore, color effects in the manner of a
multiplex board
can be generated at equal or different thicknesses of the first and at least
second ve-
neers arranged on top of one another on the side faces or chamfers of the
supporting
plate by arranging veneers on top of one another that have different colors.
The more
veneers are arranged on top of one another, the more pronounced this effect
will be.
The method according to the invention works if all synthetic resin is applied
to a
surface of the supporting plate or a veneer. Preferably, the synthetic resin
applied in
excess is applied to the first surface of the supporting plate or a surface of
the veneer
that is a non-external surface, i.e., which is not the outer surface in the
stack of material
to be pressed or in the finished wooden material, which is in contact with the
press
plate, or which represents the surface of the wooden material. Further, it is
preferred if
the synthetic resin applied in excess is applied in at least two partial
quantities to a
surface of the supporting plate and/or a veneer. For example, a first partial
quantity of
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 4 -
the synthetic resin applied in excess is applied to the first surface of the
supporting
plate and the side of the first veneer opposite the second veneer, or to the
side of the
first veneer facing the supporting plate and the side of the second veneer
facing the first
veneer. Alternatively, both sides of the first veneer can each have applied to
them a
partial quantity of the synthetic resin which is applied in excess. Further
alternatives
result without constraints. The advantage of the synthetic resin applied in
partial
quantities is that the distribution of the synthetic resin ¨ and thereby the
bond between
the veneers and the supporting plate ¨ can be achieved particularly quickly
and uni-
formly.
The method according to the invention provides that the stack of material to
be pressed
is compressed in a high-pressure press, typically a continuous or short-cycle
press. The
synthetic resin liquefied again at press-forming temperatures is compressed
into the
less dense veneer in this step; the typically denser surface of the supporting
plate
is absorbs less synthetic resin. At the same time, the veneer is compressed
by the pressure
exerted by the high-pressure press. Both effects act in synergistic
combination and
increase the compressive strength of the veneer surface. The higher density
after
compression of the veneer is as much a contribution to a higher compressive
strength
as the at least portion-wise impregnation of the veneer with synthetic resin.
Both
measures contradict the usual measures for producing a wooden material with a
veneer
surface. On the one hand, synthetic resin which serves only to affix the
veneer to the
supporting plate is typically used sparingly with up to 100 g/m2 (in relation
to 100 %)
of solid material, and on the other hand, the press-forming in a high-pressure
press is
avoided in order to avoid compressing the veneer. However, it has been found
that the
visual and tactile aspects of the wooden material according to the invention
remain
unchanged in their aesthetically pleasing aspect.
An essential feature of the invention is that the synthetic resin is, in
relation to the
quantity required for gluing purposes, used in excess because it is provided
that the
synthetic resin once again liquefied during the press-forming operation, will
partially
penetrate the veneer or respectively penetrate between the fibers of the
veneer and cure
there. The ingress of the synthetic resin into the veneer is not necessary for
affixing the
veneer to the supporting plate, superficial contact with the synthetic resin
is sufficient
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 5 -
for that. The excess quantity in relation to the quantity of synthetic resin
required for
gluing the veneer amounts to at least 30 %. Advantageously, the quantity of
synthetic
resin which is used for the method according to the invention amounts to more
than
50 %, preferably more than 100 %, particularly preferably more than 200 % of
the
quantity of synthetic resin required for gluing the veneer.
The introduction of substances that delay or stop the ingress of the synthetic
resin into
the veneer, e. g. sawdust, is disadvantageous. Sawdust is used in order to
prevent
synthetic resin from "breaking through", i.e., specifically the ingress of
synthetic resin
into the veneer up to the veneer surface. A current example of this is the
"Lindura"C)
board described above. Preferably, no sawdust is used within the scope of the
inven-
tion. The quantity specifications according to the invention can, based on the
typical
and known gluing of a veneer on a supporting plate and the quantities of
synthetic resin
used therefor of typically up to 100 g/m2 based on 100 % solid material, be
determined
and optimized by a specialist in the art with a few tests for orientation.
Even with a use of 130 g/m2 of synthetic resin, the positive effects of the
method
according to the invention and of the wooden material according to the
invention can
be seen. According to an advantageous embodiment of the invention, at least
150 g/m2
of synthetic resin are used in order to connect veneer and supporting plate
and to
increase the compressive strength of the veneer. Furthermore preferably, at
least 200
g/m2, in particular at least 300 g/m2, advantageously up to 400 g/m2 of
synthetic
resin are used. All figures given regarding the synthetic resin within the
context of this
invention relate to 100 % solid material. The second veneer shall, in most
applications,
be impregnated with synthetic resin only partially, starting from the
supporting plate or
respectively the first veneer. The outer-most veneer surface, which is facing
away from
the supporting plate, of the at least second or respectively outer-most veneer
is in this
case a solid wood surface. It is, however, also easily possible to impregnate
the first and
the at least second veneer completely with synthetic resin, such that the
synthetic resin
covers the outer-most veneer surface, which is facing away from the supporting
plate,
of the at least second or respectively outer-most veneer.
This excess of synthetic resin can, irrespective of whether the entire
quantity of synthe-
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 6 -
tic resin or partial quantities are applied, often not be applied to the board
in one work
operation or respectively in one layer. According to an advantageous
embodiment of
the invention, the liquid synthetic resin is applied in a first and in a
second layer,
wherein the synthetic resin applied in the first layer is optionally dried
before applying
the second layer. This process can be repeated several times, e.g. if up to
six or more
layers of synthetic resin are applied to the supporting plate. During drying
of the
synthetic resin, it must be ensured that, although the flowing capability is
reduced or
preferably stopped, the reactivity of the synthetic resin must at least
partially be re-
tained, such that a bond between supporting plate, synthetic resin, and veneer
is
generated inside the press. After the drying, a residual minimum moisture
content in
the synthetic resin of at least 0.5 percent by weight is preferably achieved.
The synthetic
resin is thus dried after being applied in liquid form, but it is not cured.
The dried
synthetic resin can be tacky. In principle, the synthetic resin could also be
applied to
the veneer, but the low strength of the veneer typically allows only for the
application of
a partial quantity of the synthetic resin.
The synthetic resin can be tinted if desired, such that optically perceivable
effects are
achieved when the synthetic resin enters the veneer, either in order to obtain
a higher-
quality optical effect in combination with other measures such as applying a
print to the
veneer, or to cover the supporting plate, for example with a particularly thin
veneer.
Frequently used color hues are tan or brown color hues.
For the implementation of the invention, synthetic resins that first liquefy
and then
cure under pressure and the effect of increased temperature, in particular
under the
press conditions described below, are suitable. Particularly typical and
suitable is
melamine resin. If needed, corundum or other known additives can be introduced
into
the melamine resin, which e. g. improve the abrasion or scratching resistance
of the
surface. Fibers, in particular cellulose fibers, preferably hornified
cellulose fibers, can
be introduced into the melamine resin for a better layer formation. The urea-
based or
polyvinyl acetate glues typically used for gluing veneer on supporting plates
are not well
suited for use in a high-pressure press, on the one hand because they will not
liquefy
under the pressure and temperature conditions applicable there, and will
consequently
not penetrate the veneer and cure there. On the other hand, e. g. urea-based
glue is not
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 7 -
fade-resistant and would result in yellowing after a short amount of time
where it
penetrated the veneer to a large extent.
The stack of material to be pressed is compressed according to the invention
in a high-
pressure press. A typical veneer press for applying veneers to supporting
plates, which
operates with a press-forming pressure of 3 N/m 2 to 5 N/m2, a press-forming
tempera-
ture of up to 120 C, and a press-forming duration of three to five minutes is
not
sufficient for compressing and curing the large quantities of synthetic resin
in an
efficient manner, in particular within an acceptable amount of time. The
pressure of the
to veneer presses furthermore is not adequate for compressing the veneers.
According to
the invention, it is therefore proposed to use high-pressure presses such as
e.g. contin-
uous presses or short-cycle presses, wherein a press-forming pressure of e.g.
between
25 N/mm2 and 50 N /mm2 can be obtained. The press-forming time in a high-
pressure
press advantageously amounts to between 20 seconds and 60 seconds. The press-
forming temperature preferably amounts to between 160 C and 200 C. Under
these
conditions, which are harsh compared to a conventional veneer press, in
particular with
regard to the press-forming pressure, it is ensured that the synthetic resin
penetrates
the veneers at least portion-wise and that the veneers are compressed.
In a wooden material according to the invention, a supporting plate and a
first and an
at least second veneer are connected to one another on a first surface of the
supporting
plate by means of synthetic resin, wherein the veneers are compressed and the
synthet-
ic resin penetrates at least the first veneer and at least 30 % of the veneer
thickness of
the at least second veneer. The first veneer need not have been penetrated by
the
synthetic resin in this context across the entire surface area along which the
first and
the second veneers are in contact with one another, but those areas where the
first
veneer is fully penetrated by the synthetic resin must merely suffice to
connect the
second veneer to the first veneer. According to a preferred embodiment, the
synthetic
resin penetrates at least 50 % of the veneer thickness, advantageously at
least 70 % of
the veneer thickness, but maximally too % of the veneer thickness of the at
least second
veneer. These figures relate to the compressed first and at least second
veneers. The
penetrating of the veneer with synthetic resin is optically detected and
measured by
measuring the thickness of the veneer in total and the share of the veneer
that was
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 8 -
impregnated with synthetic resin.
According to another embodiment of the invention, the first and at least
second veneers
are advantageously compressed by at least 30 % of the original thickness,
preferably by
at least 50 % of the original thickness. The compressing of the first and the
at least
second veneers need not take place to the same extent. If the first and the at
least
second veneers have different thicknesses, the veneers will be compressed
differently,
too. Despite the compressing, an outer veneer surface facing away from the
supporting
plate, which is attractive from an aesthetic and surface feel point of view,
is retained.
Tests have shown that the introduction of an excess quantity of synthetic
resin in
relation to the actual gluing quantity is unproblematic because the once again
liquefied
synthetic resin displaces air from the veneer during compressing and
penetrates
intermediate spaces between the wood fibers and cures there. This way, the
penetrating
synthetic resin effects an increase in compressive strength.
The above description shows the numerous advantages of the method according to
the
invention or respectively the wooden material according to the invention. The
method
proposed here can be executed easily and, due to the short press-forming
duration, also
very efficiently with known installations. Tests for profiling the wooden
material
according to the invention have shown that the edge processing can be
implemented in
an easy and precise manner; tearing on the veneer, which is unfortunately
common in
known veneer boards after an edge cut, does not occur here. The wooden
material
according to the invention is suitable not only for wall and ceiling boards,
but also for
flooring. Additionally, the wooden material is excellent for use in furniture
or furniture
parts with surfaces that are subject to stress without having to do without
the real wood
surface in such cases. In particular, the good resistance to moisture, in
particular when
the synthetic resin penetrates the veneer by more than 50 %, must be
emphasized.
The veneer surface, i.e., the visible surface of the outer or respectively the
at least
second veneer of the wooden material that is facing away from the supporting
plate can
be subjected to a surface treatment before or during, but in particular even
after com-
pressing. In particular the embossing of the wood surface in order to obtain
relief-like
or three-dimensional structures that provide e.g. a pore structure specific to
a wood-
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 9 -
type can be performed during or after the compressing of the stack of material
to be
pressed. However, the application of a print to the veneer surface, e.g. in
order to
obtain a coloration of the veneer surface that is specific to a wood type, can
also take
place, preferably after the compressing of the stack of material to be
pressed. According
to an advantageous further embodiment of the invention, the embossing and
print
application take place in an interrelated manner, such that a synchronous
decoration is
produced, wherein coloration and color arrangement as well as embossing are
harmo-
nized synchronously to one another. The embossing and print application can in
particular be used in order to lend a veneer that has low optical appeal a
higher-quality
aspect or to provide veneers arranged next to one another the optical
appearance of
which is too different with a more uniform look.
The veneer surface to which potentially a print is applied and/or which is
embossed can
then be oiled or varnished. Oiling and varnishing are common protective
measures for
veneer surfaces. Alternatively, the potentially printed and/or embossed veneer
surface
can also be coated with an overlay, i.e., a paper impregnated with synthetic
resin, as is
commonplace with predominantly laminate products. The press-forming conditions
in
a high-pressure press suffice to affix an overlay to the veneer surface.
The stack of material to be pressed can, according to another embodiment of
the
invention, also have an underlay, a paper or non-woven fabric which is
potentially
impregnated with synthetic resin, which is bonded to supporting plate and
veneer
during compressing. The underlay is typically arranged between supporting
plate and
first veneer, but it can also be arranged between the first and the second
veneers. A
paper or in particular a non-woven fabric, which is e. g. used with a grammage
of
g/m2 to 50 g/m2, provides the first and the second veneer on the wooden
material
according to the invention with a further increased compressive strength since
the non-
woven fabric distributes and deflects compressive forces acting on the
veneers. When a
ball in the drop ball test as per DIN EN 13329 acts on the veneer surface of a
wooden
30 material, the ball will leave behind a smaller ball indentation, i. e. a
smaller defor-
mation, if a non-woven fabric or a paper is arranged underneath the outer or
respec-
tively at least second veneer or underneath the first veneer. A paper or a non-
woven
fabric can also prove advantageous even if the veneer is processed with
smaller dimen-
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 10 -
sions than the supporting plate. It simplifies the assembling of the stack of
material to
be pressed substantially if the veneer pieces of the first and/or the second
veneer have
been assembled and affixed to a paper or non-woven fabric beforehand, which
has the
dimensions of the supporting plate. The composite of paper or non-woven fabric
and
veneer pieces can then be easily arranged on the supporting plate that was
coated with
the liquid and then dried synthetic resin.
If a non-woven fabric or paper is arranged, in particular under the at least
second
veneer or respectively the outer-most veneer of the wooden material according
to the
invention, such non-woven fabric or paper, which by itself already generates
an in-
crease in strength as described above, can additionally be provided with
additives that
improve e. g. flammability, conductivity, resistance to ingress of moisture,
fungi,
insects, or the like. Alternatively, the at least second or respectively the
outer-most
veneer can be provided with such additives.
On an underside of the supporting plate facing away from the first surface
coated with
the first and second veneers that are arranged on top of one another, a
backing can be
arranged according to an advantageous embodiment of the invention, which
ensures
balanced stress ratios on the two coated sides of the supporting plate. The
backing can
be embodied in different ways, e. g. by applying a paper impregnated with
resin, with a
synthetic resin layer, or by applying a veneer. Alternatively, the underside
of the sup-
porting plate can be coated with the same or a comparable sequence of a first
and an at
least second veneer, which are affixed with synthetic resin that is applied in
excess. If a
synthetic resin layer is chosen for a backing, it can optionally be provided
with fibers.
The stresses which build up on the surface of the supporting plate and
potentially in the
veneer, can potentially be reduced by moistening. Since water can still
penetrate into
the stack of material to be pressed even after the liquid synthetic resin is
dried, lower
stresses will advantageously build up in view of the excess quantity of
synthetic resin
and the water contained therein, such that a wooden material can be produced
without
a backing, or respectively the backing has to compensate for lesser forces
acting on the
material.
As a supporting plate, wooden material boards such as mineral or synthetic
resin
.7-
.
.
en
o,c)
ZS
NI
Date Regue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 11 -
bonded wooden material boards, particle boards, OSB boards, HDF boards (high-
density fiber boards or medium-density fiber boards with increased raw
density), or
medium-density fiber boards (MDF boards) can be used, but plywood boards,
veneer
boards, blockboards, laminboards, or solid wood boards can also be used. Due
to the
excess quantity of synthetic resin, the method according to the invention is
tolerant vis-
à-vis irregularities of the board surface, such that even boards with a
coarser surface
structure can be used.
The first and the at least second veneer can be a peeled veneer, a saw-cut
veneer, or a
sliced veneer. The veneer used can be embossed or a print can be applied to
it, but
veneers affixed to non-woven fabric or paper, in particular assembled veneer
pieces,
can also be used.
Details of the invention are explained in greater detail using exemplary
embodiments.
In the drawings:
Fig. 1 shows a schematic representation of the wooden material according to
the
invention,
Fig. 2 shows a schematic representation of the first and second veneers that
are fully
penetrated by synthetic resin,
Fig. 3 shows a schematic representation of the first veneer, which is fully
penetrated
by the synthetic resin, and of the second veneer, which is partially
penetrated by
synthetic resin.
Fig. 1 shows a schematic representation of the veneered wooden material 1
according to
the invention, here a supporting plate 2 with two veneers on a first surface,
the top face
3. The supporting plate 2 has a top face 3 and an underside 4. On the top face
3, a first
veneer 5a and, above it, a second veneer 5b are arranged, on the underside 4,
a backing
6 is arranged. Between supporting plate 2 and first veneer 5a, a synthetic
resin layer 7 is
arranged, wherein the synthetic resin 7 has fully penetrated the first veneer
5a and has
penetrated about 50 % of the second veneer 5b (see Fig. 2). Fig. 3 shows a
supporting
plate 2 with a first and a second veneer 5a, 5b, which are fully penetrated by
synthetic
resin.
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 12 -
With the embodiment according to Fig. 1-3, the entire synthetic resin applied
in excess
was arranged as a layer 7 on the top face 3 of the supporting plate 2.
Alternatively,
however, it is also possible to arrange the synthetic resin on a veneer
surface of the first
or second veneer. In this context, it is particularly preferred if the
synthetic resin is not
applied to the external surface of the outer-most veneer, here the second
veneer 5b. The
synthetic resin can additionally be applied in several layers, both to the
supporting
plate and to a veneer, e. g. to the top face 3 of the supporting plate 2 and
between the
first and the second veneer 5a, 5b. The application in several layers to
supporting plate
and/or veneer results in a particularly uniform distribution of the synthetic
resin.
As a supporting plate, any of the boards described above made from wood or
wooden
material can be used. The HDF boards chosen in the following can without any
prob-
lems be replaced with other board types. As a veneer, any of the veneers
mentioned
above can be used, the veneers used as an example in the following can be
replaced
with other types of veneer at any time. Both for the supporting plates and for
the
veneer, board or veneer thicknesses or the density of the veneer can vary.
In the following, specific press-forming conditions are stated for producing
the wooden
material according to the invention. It must be stated that these are merely
selected
press-forming conditions, the pressure, temperature, and time intervals stated
above
allow for a variation in press-forming conditions, for example a shortening of
the press-
forming time with increased pressure or increased temperature, or an increase
in both
parameters. The same applies to a reduction of pressure and/or temperature
with a
concomitant lengthening of the press-forming duration.
Exemplary embodiment 1:
A melamine resin (75 % solid material, applied quantity: 300 g/m2) is rolled
onto a
first surface of a large-format supporting plate, here e. g. an HDF board
(medium-
density fiber board with increased raw density, format: 2800 x 2070 x 8 mm).
This
resin is produced e.g. by adding powdered melamine resin to liquid melamine
resin (65
percent by weight). The melamine resin applied to the first surface of the
supporting
plate is dried in a circulating air dryer to a residual moisture content of
approx. 10 %.
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 13 -
Subsequently, four veneers are placed on the dried melamine resin. Such
veneers are
oak and birch veneers in alternating order with a thickness of 0.6 mm each.
The set-up
was compressed in a short-cycle press at 200 C, 400 N/cm2 press-forming
pressure,
and a press-forming time of 25 seconds. After press-forming, the thickness of
the
veneers was 1.8 mm in total. By means of a cross-cut test, the adhesion of the
veneer
layers to one another was checked after cooling. This adhesion was good, i.e.,
even the
outer-most veneer was firmly connected to the supporting plate or respectively
the
veneer arranged underneath the outer-most veneer. Afterwards, partial boards
with a
format of 2800 x 205 mm were saw-cut from the large-format board. A profile
for
laying without glue and a circumferential chamfer were milled into these
partial
boards. After laying, a multiplexed visual effect was discernable in the
visible connect
area (the chamfer).
Exemplary embodiment 2:
A melamine resin (75 % solid material, applied quantity: 300 g/m2) is rolled
onto a
large-format supporting plate, here an HDF board (medium-density fiber board
with
increased raw density, format: 2800 x 2070 x 8 mm). This resin is produced by
adding
powdered melamine resin to liquid melamine resin (65 percent by weight). The
mela-
mine resin is dried in a circulating air dryer to a residual moisture content
of approx.
10 %. Subsequently, a first veneer, a birch veneer, is placed on the melamine
resin, and
a second veneer, a mahogany veneer, is placed on the first veneer or
respectively birch
veneer. The mahogany veneer has a thickness of 0.5 mm and the birch veneer has
a
thickness of 1.5 mm. The set-up was compressed in a short-cycle press at 200
C, 400
Nicm2 press-forming pressure, and a press-forming time of 25 seconds. By means
of a
cross-cut test, the adhesion of the veneer layers to one another was checked
after
cooling. The adhesion was good. Afterwards, partial boards with a format of
2800 x
205 mm were saw-cut from the large-format board. A profile for laying without
glue
was milled into these partial boards.
The thus produced board shows a perfect mahogany surface. Contrary to a 2 mm
mahogany veneer as an alternative, the board according to the invention is
significantly
more cost effective due to the use of the cost-effective birch veneer.
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
CA 03118515 2021-05-03
- 14 -
Exemplary embodiment a:
A melamine resin (75 % solid material, applied quantity: 300 g/m2) is rolled
onto a
large-format supporting plate made from HDF (medium-density fiber board with
increased raw density, format: 2800 x 2070 x 8 mm). This resin is produced
e.g. by
adding powdered melamine resin to liquid melamine resin (65 percent by
weight). The
melamine resin is dried in a circulating air dryer to a residual moisture
content of
approx. 10 %. Subsequently, three veneers are placed on the melamine resin.
Each of
these veneers were oak veneers with a thickness of 0.7 mm. A non-woven fabric
made
from cellulose fibers with a grammage of 100 g/m2, which is equipped with
conductive
additives such as 2 percent by weight to 5 percent by weight carbon fibers or
conductive
carbon black, in relation to the non-woven fabric, is placed on top of the
first, lowest-
level veneer. The second and the third oak veneers are placed on top of this.
The set-up
was compressed in a short-cycle press at 200 C, 400 N/cm2 press-forming
pressure,
and a press-forming time of 25 seconds. The synthetic resin liquefies in the
press, it
penetrates the non-external veneers at least in portions completely and
penetrates the
outer-most veneer at least partially. By means of a cross-cut test, the
adhesion of the
veneer layers to one another was checked after cooling. The adhesion was good.
Afterwards, partial boards with a format of 2800 x 205 mm were saw-cut from
the
large-format board. On these partial boards, a profile for laying without glue
was
milled, and thereby a flooring element was produced. In the lower regions of
the
profile, in which the layer with the conductive non-woven fabric is located, a
strip of
conductive silver varnish is sprayed with regular spacing (every 5 cm), which
increases
the electric conductivity. After applying a voltage of 12 V, the flooring
element output
approx. 80 W/m2.
The thus produced partial boards have a significantly improved conductivity
compared
to similar partial boards without a conductive non-woven fabric.
;7-
.0
.0
On
o =
ZS
NI
Date Recue/Date Received 2021-05-03
